Battery shock absorber for a portable medical device

ABSTRACT

A device for delivering fluid to a user includes a housing, a drive motor assembly in the housing, other internal components in the housing, and a keypad external to the housing. The device includes a number of features and elements that enhance its operation, manufacturability, reliability, and user-friendliness. These features and elements include a shock absorbing element for a battery of the device, a keypad actuator layer that overlies a keypad assembly and forms a water resistant seal with the housing, and an offset element for a piezoelectric speaker that is located inside the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject matter described here is related to the subject matterdescribed in U.S. patent application Ser. Nos. 12/905,933, and12/905,936, both filed on Oct. 15, 2010.

TECHNICAL FIELD

Embodiments of the subject matter described herein relate generally tomedical devices such as fluid infusion devices. More particularly,embodiments of the subject matter relate to subassemblies, packagingfeatures, and housing features of a personal insulin infusion pump.

BACKGROUND

Portable medical devices are useful for patients that have conditionsthat must be monitored on a continuous or frequent basis. For example,diabetics are usually required to modify and monitor their dailylifestyle to keep their body in balance, in particular, their bloodglucose (BG) levels. Individuals with Type 1 diabetes and someindividuals with Type 2 diabetes use insulin to control their BG levels.To do so, diabetics routinely keep strict schedules, including ingestingtimely nutritious meals, partaking in exercise, monitoring BG levelsdaily, and adjusting and administering insulin dosages accordingly.

The prior art includes a number of fluid infusion devices and insulinpump systems that are designed to deliver accurate and measured doses ofinsulin via infusion sets (an infusion set delivers the insulin througha small diameter tube that terminates at, e.g., a cannula inserted underthe patient's skin) In lieu of a syringe, the patient can simplyactivate the insulin pump to administer an insulin bolus as needed, forexample, in response to the patient's current BG level.

A typical infusion pump includes a housing, which encloses a pump drivesystem, a fluid containment assembly, an electronics system, and a powersupply. The pump drive system typically includes a small motor (DC,stepper, solenoid, or other varieties) and drive train components suchas gears, screws, and levers that convert rotational motor motion to atranslational displacement of a stopper in a reservoir. The fluidcontainment assembly typically includes the reservoir with the stopper,tubing, and a catheter or infusion set to create a fluid path forcarrying medication from the reservoir to the body of a user. Theelectronics system regulates power from the power supply to the motor.The electronics system may include programmable controls to operate themotor continuously or at periodic intervals to obtain a closelycontrolled and accurate delivery of the medication over an extendedperiod.

Personal medical devices such as infusion pumps are typically powered bya battery or battery pack. For example, some medical devices can bepowered by a single AA battery. The portable nature of such devicesmeans that they might be subjected to physical impact, shock, or stress(which may result from physical activity of the user, accidental bumpinginto nearby objects, dropping of the device, etc.). The force impartedby a battery to the housing of a portable medical device couldcompromise the integrity of the housing and/or disturb the delicateoperating components inside the housing. Accordingly, it is desirable tohave a feature or component that protects the battery, the housing,and/or other elements of a medical device from battery impacts.

A number of electronic devices, including personal medical devices suchas infusion pumps, include membrane keypad assemblies that allow theuser to manipulate certain functions of the devices. Conventionalmembrane keypad assemblies usually include an underlying keypad layerand an overlying actuator layer. The bottom surface of the actuatorlayer is typically printed with graphics associated with the differentkeys or buttons and/or with decorative graphics. The actuator layer isusually attached to the keypad layer or the housing of the device usingan adhesive or bonding material. Ideally, the actuator layer is sealedaround the housing such that moisture and contaminants cannot enter thehousing. Indeed, some personal medical devices are designed to be waterresistant (to accommodate bathing, swimming, exposure to rain, etc.)and, for such devices, the actuator layer forms a water resistant sealwith the housing. In this regard, it is desirable to have a membranekeypad assembly that exhibits strong, robust, and reliable waterresistant characteristics.

Many electronic devices, including personal medical devices such asinfusion pumps, use piezoelectric speakers to generate sound. If thedevice is waterproof or water resistant, then a piezoelectric speakerwill typically be mounted against the inner wall of the housing forpurposes of transmitting sound to the outside world. For suchimplementations, the volume of sound produced by the piezoelectricspeaker will be influenced by various factors such as the shape, size,and structural features of the housing. If a piezoelectric speaker ismounted directly to a rigid case or housing of a device, however, itwill not effectively or efficiently generate sound at the desiredvolume. Accordingly, it is desirable to have a piezoelectric speakerassembly that operates effectively when mounted within a sealed rigidhousing of an electronic device.

BRIEF SUMMARY OF EMBODIMENTS

A shock absorbing element for a battery of a medical device is provided.The medical device includes a battery receptacle for the battery and anelectrical contact for the battery. The electrical contact resideswithin the battery receptacle, and the shock absorbing element iscomposed of a resilient material. The shock absorbing element includes:a perimeter sized and shaped to accommodate placement in the batteryreceptacle; a through hole formed in the resilient material, the throughhole being sized and shaped to accommodate the electrical contact; afirst side; a second side; and shock absorbing features formed on thefirst side or the second side to dissipate kinetic energy associatedwith motion of the battery relative to the battery receptacle.

Also provided is a shock absorbing assembly for a battery of a medicaldevice. The shock absorbing assembly includes: a battery sleeve to housethe battery, the battery sleeve having a base end; an electrical contactfor the battery, the electrical contact residing within the batterysleeve near the base end; and a shock absorbing element located withinthe battery sleeve near the base end, the shock absorbing elementcomposed of a resilient material having shock absorbing featuresintegrally formed therein to dissipate kinetic energy associated withmotion of the battery toward the base end.

A portable medical device is also provided. The portable medical deviceincludes: a housing; a battery sleeve inside the housing, the batterysleeve having a base end, wherein the battery sleeve accommodates abattery for the portable medical device; a battery contact locatedinside the battery sleeve near the base end; and a resilient andcompressive element located inside the battery sleeve near the base end,the battery contact protruding through the resilient and compressiveelement, wherein the resilient and compressive element dissipateskinetic energy associated with motion of the battery toward the baseend.

A medical device according to an embodiment is provided. The medicaldevice includes: a housing having a front face, a keypad mounting areaon the front face, and a sealing surface on the front face, the sealingsurface surrounding the keypad mounting area; a membrane keypad assemblycoupled to the keypad mounting area, the membrane keypad assemblycomprising a plurality of actuation components integrated therein; asealing element overlying the membrane keypad assembly and coupled tothe sealing surface to form a fluid resistant seal with the housing; anda graphic keypad overlay adhered to the sealing element, the graphickeypad overlay comprising graphical representations corresponding to theactuation components.

Also provided is a case assembly for a medical device. The case assemblyincludes: a plastic housing having a keypad mounting cavity and asealing rim integrally formed therein, the sealing rim located outsideand around the keypad mounting cavity; a membrane keypad assemblypositioned in the keypad mounting cavity, the membrane keypad assemblycomprising a plurality of actuation elements; and a plastic actuatorlayer overlying the membrane keypad assembly and comprising a pluralityof protrusions corresponding to the actuation elements and furthercomprising a perimeter area that extends beyond the membrane keypadassembly. The perimeter area is attached to the sealing rim to form afluid resistant seal between the plastic housing and the plasticactuator layer.

A method of manufacturing a medical device is also provided. The methodbegins by providing a plastic housing having a keypad mounting area anda sealing rim positioned outside the keypad mounting area. The methodcontinues by affixing a membrane keypad assembly on the keypad mountingarea, the membrane keypad assembly comprising a plurality of actuationelements. The perimeter area of a plastic actuator layer is sealed tothe sealing rim to form a fluid resistant seal between the plastichousing and the plastic actuator layer, wherein the plastic actuatorlayer overlies the membrane keypad assembly, and wherein protrusionsformed on the plastic actuator layer are aligned with the actuationelements of the membrane keypad assembly.

Another embodiment of a medical device is also provided. The medicaldevice includes: a rigid housing having an interior surface; apiezoelectric speaker enclosed within the rigid housing, thepiezoelectric speaker comprising an actuator that is controlled togenerate sound during operation of the medical device; and an offsetelement located between the interior surface and the actuator. Theoffset element, the actuator, and the interior surface at leastpartially define a resonant cavity for the piezoelectric speaker.

Also provided is a transducer assembly for a medical device having arigid housing and a flat interior surface. The transducer assemblyincludes: a piezoelectric speaker comprising an actuator; and an offsetelement for the piezoelectric speaker. The offset element has anactuator side that mates with the piezoelectric speaker, a housing sidethat mates with the flat interior surface of the rigid housing, and anopening formed therein and extending from the actuator side to thehousing side. The actuator side and the housing side are separated by anoffset thickness, and the opening and the offset thickness at leastpartially define a resonant cavity for the piezoelectric speaker.

An electronic assembly for a medical device is also provided. Theelectronic assembly includes: a carrier substrate; a piezoelectricspeaker having a first major side and a second major side, the firstmajor side coupled to the carrier substrate; and an offset ring coupledto the second major side of the piezoelectric speaker. The offset ringhas an opening formed therein through which a portion of the secondmajor side is exposed. The opening at least partially defines a resonantcavity for the piezoelectric speaker.

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 is a schematic representation of an embodiment of a fluidinfusion device;

FIG. 2 is an exploded perspective view of the fluid infusion device;

FIG. 3 is a perspective phantom view of the housing of the fluidinfusion device;

FIG. 4 is an exploded perspective view of a battery tube subassemblysuitable for use with the fluid infusion device;

FIG. 5 is a perspective view of a spring support disk of the batterytube subassembly;

FIG. 6 is a perspective view of a vibration motor support disk of thebattery tube subassembly;

FIG. 7 is a perspective view of a shock absorbing element suitable foruse within the battery tube subassembly of the fluid infusion device;

FIG. 8 is a top view of the shock absorbing element;

FIG. 9 is a side view of the shock absorbing element;

FIG. 10 is a perspective cross sectional view of a portion of the fluidinfusion device, depicting the shock absorbing element installed in abattery sleeve;

FIG. 11 is an exploded perspective view of an electronics assemblysuitable for use with the fluid infusion device;

FIG. 12 is a top perspective view of an offset element for apiezoelectric speaker;

FIG. 13 is a bottom perspective view of the offset element;

FIG. 14 is a top view of the offset element;

FIG. 15 is a bottom view of the offset element;

FIG. 16 is a cross sectional view of the offset element, as viewed alongline 16-16 of FIG. 15;

FIG. 17 is a cross sectional side view of a portion of the electronicsassembly shown in FIG. 2;

FIG. 18 is an exploded perspective view of the electronics assemblyshown in FIG. 2;

FIG. 19 is an exploded perspective view of the fluid infusion device;

FIG. 20 is a perspective view of an assembly shim suitable for use withthe fluid infusion device;

FIG. 21 is a perspective view of a motor support cap suitable for usewith the fluid infusion device;

FIG. 22 is a top view of the motor support cap;

FIG. 23 is a front elevation view of the motor support cap;

FIG. 24 is a side elevation view of the motor support cap;

FIG. 25 is an exploded perspective view of a portion of the fluidinfusion device;

FIG. 26 is a perspective view of the fluid infusion device shown in FIG.25, after installation of the motor support cap;

FIG. 27 is an exploded front perspective view of the fluid infusiondevice, showing a case bottom dampener;

FIG. 28 is an exploded rear perspective view of the fluid infusiondevice, showing the case bottom dampener;

FIG. 29 is a perspective cross sectional view of the bottom end of thefluid infusion device;

FIG. 30 is a perspective front view of the housing of the fluid infusiondevice;

FIG. 31 is a cross sectional view of the housing, as viewed from line31-31 in FIG. 30;

FIG. 32 is a perspective front view of a membrane keypad assemblysuitable for use with the fluid infusion device;

FIG. 33 is a perspective front view of the fluid infusion device priorto installation of a keypad actuator layer;

FIG. 34 is a perspective front view of the fluid infusion device priorto installation of a graphic keypad overlay;

FIG. 35 is a perspective back view of the fluid infusion device prior toinstallation of a decorative back cover;

FIG. 36 is a side view of a belt clip suitable for use with the fluidinfusion device; and

FIG. 37 is an exploded perspective view of the belt clip shown in FIG.36.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

Certain terminology may be used in the following description for thepurpose of reference only, and thus are not intended to be limiting. Forexample, terms such as “upper”, “lower”, “above”, and “below” refer todirections in the drawings to which reference is made. Terms such as“front”, “back”, “rear”, “side”, “outboard,” and “inboard” describe theorientation and/or location of portions of the component within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport. Similarly, the terms “first”, “second” and other such numericalterms referring to structures do not imply a sequence or order unlessclearly indicated by the context.

For or the sake of brevity, conventional features and characteristicsrelated to infusion system operation, insulin pump and/or infusion setoperation, blood glucose sensing and monitoring, force sensors, signalprocessing, and other functional aspects of an infusion device (and theindividual operating components of the infusion device) may not bedescribed in detail here. Examples of infusion pumps and/or related pumpdrive systems used to administer insulin and other medications may be ofthe type described in, but not limited to, U.S. Pat. Nos.: 4,562,751;4,678,408; 4,685,903; 5,080,653; 5,505,709; 5,097,122; 6,485,465;6,554,798; 6,558,351; 6,659,980; 6,752,787; 6,817,990; 6,932,584; and7,621,893; which are herein incorporated by reference.

The subject matter described here relates to various features,components, assembly methodologies, and technology associated with afluid infusion device of the type used to treat a medical condition of apatient. The infusion device is used for infusing fluid into the body ofa user. The non-limiting examples described below relate to a medicaldevice used to treat diabetes (more specifically, an insulin pump),although embodiments of the disclosed subject matter are not so limited.Accordingly, the infused fluid is insulin in certain embodiments. Inalternative embodiments, however, many other fluids may be administeredthrough infusion such as, but not limited to, disease treatments, drugsto treat pulmonary hypertension, iron chelation drugs, pain medications,anti-cancer treatments, medications, vitamins, hormones, or the like.

FIG. 1 is a schematic representation of an embodiment of a fluidinfusion device 100, and FIG. 2 is an exploded perspective view of thefluid infusion device 100. FIG. 1 also shows an infusion set 102 coupledto the fluid infusion device 100. The fluid infusion device 100 isdesigned to be carried or worn by the patient. The fluid infusion device100 may leverage a number of conventional features, components,elements, and characteristics of conventional and well known fluidinfusion devices. For example, the fluid infusion device 100 mayincorporate some of the features, components, elements, and/orcharacteristics described in U.S. Pat. Nos. 6,485,465 and 7,621,893, therelevant content of which is incorporated by reference herein.

Referring to FIG. 1, the fluid infusion device 100 includes a userinterface 104 that includes several buttons that can be activated by theuser. These buttons can be used to administer a bolus of insulin, tochange therapy settings, to change user preferences, to select displayfeatures, and the like. Although not required, the illustratedembodiment of the fluid infusion device 100 includes a display element106. The display element 106 can be used to present various types ofinformation or data to the user, such as, without limitation: thecurrent glucose level of the patient; the time; a graph or chart of thepatient's glucose level versus time; device status indicators; etc. Insome embodiments, the display element 106 is realized as a touch screendisplay element and, therefore, the display element 106 also serves as auser interface component.

The fluid infusion device 100 accommodates a fluid reservoir (hiddenfrom view in FIG. 1) for the fluid to be delivered to the user. A lengthof tubing 108 fluidly couples the fluid reservoir to the infusion set102. The tubing 108 extends from the fluid infusion device 100 to theinfusion set 102, which provides fluid communication with the body ofthe user. A removable cap or fitting 110 is suitably sized andconfigured to accommodate replacement of fluid reservoirs (which aretypically disposable) as needed. In this regard, the fitting 110 isdesigned to accommodate the fluid path from the fluid reservoir to thetubing 108.

For the sake of brevity, FIG. 2 is a simplified depiction of the fluidinfusion device 100, which does not include all of the elements,components, and features that would otherwise be present in a typicalembodiment. It should be appreciated that a deployed implementation ofthe fluid infusion device 100 will include additional features,components, and elements that are not shown in the figures. FIG. 2 alsodepicts an exemplary fluid reservoir 111 that can be installed into thefluid infusion device 100.

The embodiment of the fluid infusion device 100 illustrated in FIG. 2includes a housing 112 and a housing end cap 114 that is coupled to anend 116 of the housing 112 to enclose components within the housing 112.These internal components include, without limitation: a battery tubesubassembly 118; a sleeve 120; a slide 121; an electronics assembly 122;a drive motor assembly 124 having a drive screw 125; a force sensor 126;and a motor support cap 128. FIG. 2 also depicts some components thatare located outside the housing 112, namely, a battery cap 129, a keypadassembly 130, a back cover 131, and a graphic keypad overlay 132 for thekeypad assembly 130. The keypad assembly 130 and the graphic keypadoverlay 132 may be considered to be part of the user interface 104 ofthe fluid infusion device 100.

The battery tube subassembly 118 accommodates a battery or battery pack,which serves as the primary power supply for the electronics module,infusion pump hardware, and other electronic components of the fluidinfusion device 100. As shown in FIG. 2, the battery tube subassembly118 is positioned at one side of the housing 112 (to provide clearanceand space for the remaining internal components). A detailed descriptionof the battery tube subassembly 118 appears below in a separate sectionof this specification.

When the fluid infusion device 100 is assembled, the sleeve 120 ispositioned at the side of the housing 112 opposite the battery tubesubassembly 118. The sleeve 120 serves as a keying feature to preventthe slide 121 from rotating when the drive screw 125 of the drive motorassembly 124 rotates. The sleeve 120 receives the slide 121, which hasinternal threads for assembly onto the drive screw 125. Thus, rotationof the drive screw 125 causes the slide 121 to extend or retractrelative to the drive motor assembly 124. When the fluid infusion deviceis assembled and operational, the slide 121 contacts a plunger 133 toengage the fluid reservoir 111 and control delivery of fluid from thefluid infusion device 100.

The electronics assembly 122 includes a carrier substrate 134, such as aprinted circuit board or other structure, upon which various electronicand other components are mounted. In this regard, the electronicsassembly 122 may include a suitably configured electronics module, whichmay include or cooperate with a power supply, at least one memoryelement, at least one processor, processing logic, and device software,firmware, and application programs. Moreover, the illustrated embodimentof the electronics assembly 122 includes a piezoelectric speaker 136that is coupled to the carrier substrate 134. A detailed description ofthe piezoelectric speaker 136 appears below in a separate section ofthis specification.

The fluid infusion device 100 cooperates with a fluid reservoir 111,which is actuated to deliver measured doses of fluid to the user via theinfusion set 102 (see FIG. 1). While certain embodiments accommodatedisposable, prefilled reservoirs, alternative embodiments may userefillable cartridges, syringes or the like. A cartridge can beprefilled with insulin (or other drug or fluid) and inserted into thehousing 112. Alternatively, a cartridge could be filled by the userusing an appropriate adapter and/or any suitable refilling device.

When the fluid infusion device 100 is assembled, the drive motorassembly 124 is located in the housing 112 and is covered by the housingend cap 114. The force sensor 126 is positioned below the drive motorassembly 124, and the force sensor 126 is covered by the motor supportcap 128, which in turn is covered by the housing end cap 114. A detaileddescription of the motor support cap 128 appears below in a separatesection of this specification.

In one implementation, the force sensor 126 is affixed to the base end138 of the drive motor assembly 124 such that the force sensor 126reacts when the combination of the drive motor assembly 124 and theforce sensor 126 bears against the motor support cap 128. In anotherimplementation, the force sensor 126 is affixed to the motor support cap128 such that the force sensor 126 reacts when the drive motor assembly124 bears against the force sensor 126. The configuration andarrangement of the drive motor assembly 124 and the force sensor 126allows the force sensor 126 to react to forces imparted thereto by thedrive motor assembly 124 and/or forces imparted to the drive motorassembly 124 via the fluid pressure of the fluid reservoir.

The drive motor assembly 124 includes an electric motor that is actuatedand controlled by the electronics module of the fluid infusion device100. The motor is preferably realized as a brushless DC motor thatrotates in a stepwise or discrete manner corresponding to the desirednumber of fluid delivery strokes. Alternatively, the motor could be a DCmotor, a solenoid, or the like. The motor may optionally include anencoder, which cooperates with the electronics module of the fluidinfusion device 100 to monitor the number of motor rotations or portionsthereof. This in turn can be used to accurately determine the positionof the slide 121, thus providing information relating to the amount offluid dispensed from the fluid reservoir, which is actuated by movementof the slide 121.

The illustrated embodiment of the slide 121 includes a coupler 142,which may be attached to or integrated with the slide 121, as depictedin FIG. 2. The slide 121 is sized to fit within the housing of the fluidreservoir 111, which enables the slide 121 to operatively cooperate withthe fluid reservoir 111. In this regard, the slide 121 serves as alinear actuation member for the fluid reservoir 111. The fluid reservoir111 includes a plunger 133 or piston with at least one sealing elementor feature (e.g., one or more O-rings, integral raised ridges, or awasher) for forming a fluid and air tight seal with the inner wall ofthe fluid reservoir 111. As mentioned previously, the fluid reservoir111 is secured into the housing 112 with the fitting 110, which alsoserves as the interface between the fluid reservoir 111 and the infusionset tubing 108 (see also FIG. 1). For this embodiment, the piston of thefluid reservoir 111 is connected to the slide 121 by a releasablecoupling mechanism or feature. For example, the piston may have a femaleportion that receives the coupler 142. The female portion is positionedat the end face of the piston, and it could include a threaded cavitythat engages threads of the coupler 142.

During operation of the fluid infusion device 100, rotation of the driveshaft of the drive motor assembly 124 rotates the drive screw 125, whichin turn moves the slide 121, relative to the base end 138 of the drivemotor assembly 124. Thus, rotation of the drive shaft results in axialdisplacement of the slide 121 and, therefore, axial displacement of thecoupler 142. Such displacement of the coupler 142 moves the piston ofthe fluid reservoir 111 to deliver a predetermined or commanded amountof medication or liquid from the fluid infusion device 100. As describedabove, if a stepper motor is employed, then the drive motor assembly 124can regulate delivery of fluid from the fluid infusion device 100 indiscrete actuation or delivery strokes. In some embodiments, the driveshaft of the drive motor assembly 124 and the slide 121 are coaxiallycentered within the longitudinal axis of travel of the piston. Incertain alternative embodiments, one or more of these components may beoffset from the center of the axis of travel.

As mentioned above, certain embodiments of the fluid infusion device 100accommodate removable and replaceable fluid reservoirs. When the slide121 (and, therefore, the piston of the fluid reservoir 111) is in itsfully extended position, the piston has forced most, if not all, of thefluid out of the fluid reservoir 111. After the piston has reached theend of its travel path, indicating that the fluid reservoir 111 has beendepleted, the fluid reservoir 111 may be removed by disengaging theplunger 133 from the coupler 142 of the slide 121. After the empty (orotherwise used) fluid reservoir 111 is removed, the electronics moduleor control system of the fluid infusion device 100 initiates a rewindoperation during which the motor rotates in the reverse direction torewind the slide 121 back to its fully retracted position. Thereafter, anew or refilled fluid reservoir can be installed, seated, and primed foruse. In operation, the force sensor 126 may be used to determine whenthe slide 121 contacts the piston, when the coupler 142 is properlyseated in the female portion of the piston, when the fluid reservoir 111has been primed and is ready to deliver measured doses of fluid, when anocclusion is present in the fluid flow path, and/or when the fluidinfusion device 100 has been subjected to shock or impact.

The keypad assembly 130 is coupled to a keypad mounting area 144 of thehousing 112, and the graphic keypad overlay 132 overlies the keypadassembly 130. The keypad assembly 130 includes features corresponding tokeys, buttons, switches, or other user interface items, and the graphickeypad overlay 132 may include visual indicia associated with theactuation elements of the keypad assembly 130, decorative graphics,alphanumeric labeling, etc. A detailed description of the keypadassembly 130 and the graphic keypad overlay 132 appears below in aseparate section of this specification.

The fluid infusion device 100 may be manufactured and assembled in themanner summarized below, and using the techniques, technology, andapproaches described in more detail in the separate sections of thisspecification. The following description of an exemplary assemblyapproach is not intended to be limiting or exhaustive and, indeed,alternative fabrication and assembly techniques could be utilized toproduce the fluid infusion device 100. Moreover, it may be possible ordesirable to reorder some of the assembly steps described below,depending upon the particular circumstances and capabilities of themanufacturing facility.

For this example, the battery tube subassembly 118 is assembled (seeFIG. 3) so that it can be integrally molded into the housing 112. Inthis regard, the housing 112 is preferably realized as a molded hardplastic shell, which provides a strong, stiff, and rigid protective casefor the internal components of the fluid infusion device 100. The keypadassembly 130 can then be bonded to the keypad mounting area 144. Thekeypad assembly 130 can be installed by feeding its flex circuit tail146 through a corresponding slot 148 in the housing 112. As described inmore detail below, a sealing element (not separately shown in FIG. 2)may be installed overlying the keypad assembly 130 to form a fluidresistant seal with the housing 112. Next, the pre-assembled electronicsassembly 122 is inserted into the housing 112 while keeping the flexcircuit tail 146 of the keypad assembly 130 clear. The force sensor 126is then bonded to the base end 138 of the drive motor assembly 124, andthe slide 121 is installed onto the drive screw 125. Accordingly, thedrive motor assembly 124 and the force sensor 126 together form asubassembly that is later installed into the housing 112. Thereafter,the sleeve 120 is inserted over the slide 121 and keyed in place. Aslide seal 149 is installed onto the slide 121 and bottomed out againstthe sleeve 120. The subassembly (including the drive motor assembly 124,the attached force sensor 126, the slide 121, and the sleeve 120) isthen inserted into the housing 112.

Electrical connections are then established from the drive motorassembly 124, the force sensor 126, and the keypad assembly 130 to theelectronics assembly 122 using suitable conductors, e.g., the flexcircuit tail 146, flex cables, wires, or the like. For example, contactson the battery tube subassembly 118 are connected to correspondingcontact points or conductors on the electronics subassembly 122. Asshown in FIG. 2, the drive motor assembly 124 has an electrical lead150, and the force sensor 126 has an electrical lead 152. Theseelectrical leads 150, 152, along with the flex circuit tail 146 of thekeypad assembly 130, are connected (directly or indirectly) toappropriate points, receptacles, or conductors on the electronicsassembly 122. In addition, electrical connections are established for arechargeable battery and a vibrator motor (not shown).

Next, an assembly shim 153 is inserted into the housing 112 to bias theelectronics subassembly 122 towards a display window of the housing 112and to “lock” the internal components in place. As described in moredetail below, the assembly shim 153 also holds certain leads, flexcircuit elements, and/or wires in place for ease of assembly.Thereafter, the motor support cap 128 is installed over the force sensor126 and the base end 138 of the drive motor assembly 124, and secured tothe interior surface of the housing 112 (as described in more detailbelow). A dampener element (not shown) is installed onto the housing endcap 114, which is then attached to the end 116 of the housing 112 toenclose the internal components within the housing 112. In practice, thehousing end cap 114 can be ultrasonically welded to the housing 112. Thegraphic keypad overlay 132 is then adhered to the keypad assembly 130(and/or to the sealing element).

The fluid infusion device 100 employs a number of features, components,and elements that enhance its performance, user-friendliness,manufacturability, robustness, and the like. For ease of description,some of these features, components, and elements will be presented belowunder their respective section headings. In practice, the fluid infusiondevice 100 could implement some or all of the features, components, andelements described below.

Battery Tube Subassembly

As mentioned above with reference to FIG. 2, the fluid infusion device100 includes a battery tube subassembly 118 located inside the housing112. FIG. 3 is a perspective phantom view of the housing 112; thebattery tube subassembly 118 is shown in its installed position insidethe housing 112. The battery tube subassembly 118 is accessible from thetop end 200 of the housing 112, via a cap or fitting 202. The fitting202 allows the user to remove and replace the battery or battery pack asneeded. In practice, the fitting 202 is fluid resistant to inhibit theincursion of fluid (e.g., water) and contaminants into the battery tubesubassembly 118.

FIG. 4 is an exploded perspective view of the battery tube subassembly118. This particular embodiment of the battery tube subassembly 118includes, without limitation: a battery sleeve 204; a spring supportdisk 206; a vibration motor support disk 208; a spring 210 (or othersuitable electrical contact); and a shock absorbing element 212. FIG. 5is a perspective view of the spring support disk 206, and FIG. 6 is aperspective view of the vibration motor support disk 208. A detaileddescription of the shock absorbing element 212 appears below in aseparate section of this specification.

The battery tube subassembly 118 is suitably configured so that it canbe molded into the housing 112 (see FIG. 3). This reduces part count inthe final assembly and creates a permanent bond between the batterysleeve 204 and the housing 112. Moreover, the battery sleeve 204 becomespart of the housing 112, thus eliminating a leak path, adding strength,reducing assembly steps, and reducing cost.

In certain implementations, the battery sleeve 204 is drawn and formedto size from stainless steel with a tang 214 extending from the rolledend. The tang 214 is the positive contact that is soldered to the powerboard at the next higher assembly level. The rolled end is used tocapture the spring support disk 206, which forms the bottom end cap ofthe battery compartment defined inside the battery sleeve 204. Inpractice, the battery sleeve 204 is shaped and sized to accommodate thedimensions of the battery or battery pack, e.g., a AA battery.

For this embodiment, the spring support disk 206 is molded frompolycarbonate or a similar material. The spring support disk 206 becomesthe inside component at the end of the battery sleeve 204. The springsupport disk 206 supports the spring 210 and provides features tocapture the spring 210 and hold it in position. An energy director ring215 is provided on the spring support disk 206. The energy director ring215 is designed to facilitate welding of the spring support disk 206 tothe vibration motor support disk 208, thereby pinching the rolled end ofthe battery sleeve 204 between the spring support disk 206 and thevibration motor support disk 208 and creating a solid bottom to thebattery sleeve 204.

The vibration motor support disk 208 may also be molded frompolycarbonate. The vibration motor support disk 208 becomes the externalcomponent at the end of the battery sleeve 204. The vibration motorsupport disk 208 has a through hole for the spring 210 and the tang 214of the battery sleeve 204. The vibration motor support disk 208 iswelded to the spring support disk 206 and, therefore, forms the bottomof the battery sleeve 204. The vibration motor support disk 208 isdesigned to fit the vibration motor. In this regard, the vibration motorsupport disk 208 has two walls 216 that allow the vibration motor to bebonded to the vibration motor support disk 208 at the next assemblylevel. An ultraviolet cure adhesive is used to bond the vibration motor(not shown) to the vibration motor support disk 208 in the finalassembly.

The spring 210 represents the negative electrical contact for thebattery or battery pack. In certain embodiments, the spring 210 iscoiled from beryllium copper wire (or other electrically conductivemetal) for strength and low electrical resistance. The spring 210 has anend leg 218 that passes through both the spring support disk 206 and thevibration motor support disk 208. The spring 210 is held in place on thespring support disk 206 with features that snugly fit inside the lastcoil. The end leg 218 of the spring 210 passes through the vibrationmotor support disk 208 and it is soldered to the power board as thenegative contact.

The components of the battery tube subassembly 118 can be assembled asfollows. The spring 210 is located on the spring support disk 206, whichis then inserted into the battery sleeve 204 and against the rollededge. The vibration motor support disk 208 is then placed against thespring support disk 206 and the outside rolled edge of the batterysleeve 204, and then welded together using an ultrasonic welder. Thiscreates the bottom or base end for the battery sleeve 204. That assemblyis then placed on the core of the molding machine and inserted into themold. The housing 112 is then molded over the battery tube subassembly118 to create a very clean one-piece housing with an integrated batterycompartment or receptacle. The shock absorbing element 212 can beinstalled into the battery sleeve 204 and around the spring 210 aftercompletion of the molding process.

Shock Absorbing Element

As mentioned in the preceding section, the shock absorbing element 212is installed inside the battery tube subassembly 118, which serves asthe battery receptacle for the fluid infusion device 100. FIG. 7 is aperspective view of the shock absorbing element 212, FIG. 8 is a topview of the shock absorbing element 212, FIG. 9 is a side view of theshock absorbing element 212, and FIG. 10 is a perspective crosssectional view of a portion of the fluid infusion device 100 (FIG. 10depicts the shock absorbing element 212 as installed). For thisembodiment, the bottom view of the shock absorbing element 212 issimilar or identical to its top view.

The illustrated embodiment of the shock absorbing element 212 isring-shaped, and it surrounds the spring 210 (see FIG. 10). In otherwords, when the shock absorbing element 212 installed properly near thebase end of the battery sleeve 204, the spring 210 protrudes through theshock absorbing element 212. Referring again to FIG. 4, the base end ofthe battery sleeve 204 corresponds to the top surface of the springsupport disk 206 in this embodiment. Consequently, after the battery isinserted into the battery sleeve 204, the shock absorbing element 212will reside between the base end of the battery sleeve 204 and thebattery.

The shock absorbing element 212 is designed to absorb the shock from thebattery (e.g., a AA sized battery) or battery pack housed inside thebattery sleeve 204. The shock absorbing element 212 is placed at thebottom of the battery sleeve 204, and attached to the base end using,for example, an adhesive. As shown in FIG. 10, the shock absorbingelement 212 is located around the spring 210, which resides within thebattery sleeve 204 near the base end. This configuration protects thespring 210 against over compression by stopping the battery above thecompressed “solid” height of the spring 210, which could cause damage tothe fluid infusion device 100. In certain embodiments, the shockabsorbing element 212 is compression molded and composed of a resilientelectrical insulator material, such as rubber, polyurethane, plastic, orthe like, which has properties that increase its shock absorbingcharacteristics. Thus, the shock absorbing element 212 is preferablyformed as a one-piece component composed of the chosen resilientmaterial. Moreover, the shape of the shock absorbing element 212 issuitably designed with various shock absorbing features integrallyformed therein; these integral features improve the ability of the shockabsorbing element 212 to absorb loads and dissipate kinetic energy thatmight be associated with motion of the battery toward the base end. Inpractice, the shock absorbing element 212 reduces shock loadstransmitted from the battery to the housing 112.

Referring to FIGS. 7-9, the shock absorbing element 212 has a throughhole 219 formed therein, an outer perimeter 220 (which corresponds tothe outer circumference when the perimeter is circular), and an innercircumference 222 that is defined by the edge of the through hole 219.The outer perimeter 220 is sized and shaped to accommodate placement ofthe shock absorbing element 212 in the battery sleeve 204. In thisregard, the outer perimeter 220 could be sized for a press fit in thebattery sleeve 204 or, in the alternative, to provide some clearancebetween the shock absorbing element 212 and the inner wall of thebattery sleeve 204. Some amount of clearance may be desirable to allowthe shock absorbing element to compress, expand, and deform in responseto forces imparted thereto.

The through hole 219 is sized and shaped to accommodate the spring 210,as depicted in FIG. 10. For this particular embodiment, the through hole219 is generally round or circular when viewed from the top or bottom,as shown in FIG. 8. Moreover, the outer perimeter 220 and the throughhole 219 are coaxial in the illustrated ring-shaped embodiment.

The shock absorbing element 212 has a top side 224 (which faces thebattery) and a bottom side 226 (which faces the base end of the batterysleeve 204)—FIG. 8 shows the top side 224. Notably, the shock absorbingelement 212 has at least one shock absorbing feature integrally formedon its top side 224 and/or at least one shock absorbing feature formedon its bottom side 226, and these shock absorbing features are designedto dissipate kinetic energy associated with motion of the batteryrelative to the battery sleeve 204. Depending upon the particularembodiment, a shock absorbing feature may be, without limitation: aradial ridge formed from the resilient material; a radial depressionformed in the resilient material; an angled or tilted outer depressionformed in the resilient material; an angled or tilted inner depressionformed in the resilient material; a rib; a protrusion; a hole; texture;a rim; or the like.

The illustrated embodiment of the shock absorbing element 212 employs analternating pattern of angled depressions on each side. Morespecifically, the top side 224 has a plurality of angled outerdepressions 228 interlaced with a plurality of angled inner depressions230. Each of the angled outer depressions 228 has a high edge locatednear or terminating at the through hole 219, and a low edge located nearor terminating at the outer perimeter 220. Thus, the angled outerdepressions 228 are downwardly sloped toward the outer perimeter (seethe side view of FIG. 9). In contrast, each of the angled innerdepressions 230 has a high edge located near or terminating at the outerperimeter, and a low edge located near or terminating at the throughhole 219. Accordingly, the angled inner depressions 230 are downwardlysloped toward the through hole 219 (see FIG. 7).

In certain embodiments, at least one angled outer depression is formedon each side of the shock absorbing element 212, and at least one angledinner depression is formed on each side of the shock absorbing element212. For this example, the bottom side 226 of the shock absorbingelement 212 may also have four angled outer depressions and four angledinner depressions formed therein, and the depressions may be arranged inan alternating manner. Moreover, each angled outer depression formed onthe top side 224 is aligned with a respective angled inner depressionformed on the bottom side 226, and each angled outer depression formedon the bottom side 226 is aligned with a respective angled innerdepression formed on the top side 224. This aligned relationship isshown in FIG. 7 and FIG. 9, where depressions formed in the bottom side226 are identified using prime notation. Thus, the angled innerdepressions 230 on the top side 224 are aligned with the angled outerdepressions 228′ on the bottom side 226, and the angled outerdepressions 228 on the top side 224 are aligned with the angled innerdepressions 230′ on the bottom side 226.

The depressions formed in the shock absorbing element 212 are radiallyoriented in that they resemble longitudinal channels that run in theradial direction. Note that the configuration of the depressions alsoforms a number of radial ridges in the resilient material. These radialridges are located between the depressions on each side of the shockabsorbing element 212. The depressions, radial ridges, and otherfeatures of the shock absorbing element 212 contribute to itscompressive, rebound, and energy absorbing characteristics.

Piezoelectric Speaker Offset Element

As mentioned above with reference to FIG. 2, the electronics assembly122 of the fluid infusion device 100 might include at least onepiezoelectric speaker 136 on the carrier substrate 134. FIG. 11 is aperspective view of the electronics assembly 122, with a transducerassembly 300 shown in exploded form. The illustrated embodiment of thetransducer assembly 300 includes the piezoelectric speaker 136, anoffset element 302, and a mounting component 304.

In a conventional piezoelectric speaker mounting environment, thepiezoelectric speaker is mounted directly to a surface, such as theinterior surface of the case or housing of the device. This typicallyworks for systems that have through holes in the case or housing(through which sound generated by the speaker is emitted). The fluidinfusion device 100, however, employs a fluid resistant housing 112 thatdoes not contain any sound-transmitting holes.

The piezoelectric speaker 136 functions by vibrating to produce sounds.If the piezoelectric speaker 136 is mounted directly to a relativelyrigid housing (such as hard plastic), the piezoelectric speaker cannotefficiently and effectively vibrate the housing.

Thus, the speaker does not efficiently produce sounds. To address thisshortcoming of traditional designs, the transducer assembly 300 employsthe offset element 302, which creates a gap between the actuator of thepiezoelectric speaker 136 and the rigid plastic of the housing 112. Thegap allows the piezoelectric speaker 136 to easily vibrate the airbetween the inner surface of the housing 112 and the surface of thepiezoelectric speaker 136. When the resonant frequency of the system isreached, the air vibrates violently and the vibrations are transmittedto the rigid plastic of the housing 112. The magnitude of the vibrationsis generally much higher relative to an arrangement where thepiezoelectric speaker is mounted directly to a housing.

Referring to FIG. 11, the transducer assembly 300 is coupled to thecarrier substrate 134 by way of the mounting component 304. In thisregard, the illustrated embodiment of the piezoelectric speaker 136 isrealized as a flat disk having a top major side 306 and a bottom majorside 308. The bottom major side 308 is attached to the upper surface 310of the mounting component 304, and the lower surface 312 of the mountingcomponent is attached to the carrier substrate 134. In practice,pressure sensitive adhesive can be used to affix the mounting component304 to the carrier substrate 134, and to affix the piezoelectric speaker136 to the mounting component 304. Although not depicted in the figures,appropriate electrical connections are established between thepiezoelectric speaker 136 and corresponding contact points formed on thecarrier substrate 134, as is well understood by those familiar withelectric transducers. For example, conductive wires, ribbons, or tracesmay be routed from the piezoelectric speaker 136, through the center ofthe mounting component 304, and to carrier substrate 134. Alternatively,conductive wires, ribbons, or traces could be routed between the uppersurface 310 of the mounting component 304 and the bottom major side 308of the piezoelectric speaker 136.

In certain embodiments, the mounting component 304 is a ring-shapedelement formed from a resilient material such as rubber, foam,polyurethane, or the like. The resiliency of the mounting component 304results in biasing of the piezoelectric speaker 136 away from thecarrier substrate 134 in the absence of other external forces. Thus,force applied to the top of the piezoelectric speaker 136 and/or to thetop of the offset element 302 will compress the mounting component 304.Removal of the applied force, however, will allow the mounting component304 to decompress and spring back into its nominal shape andconfiguration. The resilient nature of the mounting component 304 allowsit to bias the offset element 302 against the interior surface of thehousing 112 (as explained below).

The top major side 306 of the piezoelectric speaker 136 is coupled tothe offset element 302. For this particular embodiment, the offsetelement 302 is coupled to the piezoelectric speaker 136 by way of a snapfit or press fit engagement. In this regard, clips or tab features (seeFIG. 13) can be used to secure the piezoelectric speaker 136 to theoffset element 302. The offset element 302 (which is ring-shaped in thisembodiment) has an opening 314 formed therein, through which a portionof the top major side 306 is exposed (see FIG. 2). As explained in moredetail below, the opening 314 at least partially defines a resonantcavity for the piezoelectric speaker 136.

When assembled, the carrier substrate 134, the piezoelectric speaker136, and the offset element 302 together form a subassembly (which maybe part of the electronics assembly 122) that can be inserted into therigid housing 112. Moreover, when assembled, the mounting component 304compresses the transducer assembly 300 against the interior wall orsurface of the housing 112, which causes the piezoelectric speaker 136to sit firmly against the offset element 302. The offset element 302 isused to maintain the actuator of the piezoelectric speaker 136 in adisplaced position relative to the interior surface of the housing 112(see FIG. 17). FIG. 12 is a top perspective view of the offset element302, FIG. 13 is a bottom perspective view of the offset element 302,FIG. 14 is a top view of the offset element 302, FIG. 15 is a bottomview of the offset element 302, FIG. 16 is a cross sectional view of theoffset element 302 as viewed along line 16-16 of FIG. 15, and FIG. 17 isa cross sectional side view of a portion of the electronics assembly 122shown in FIG. 2.

Although not always required, the illustrated embodiment of the offsetelement 302 is a round, generally ring-shaped shim that is shaped andsized for coupling around the outer perimeter of the piezoelectricspeaker 136. The offset element 302 is formed from a rigid material suchas hard plastic. In certain embodiments, the offset element 302 isformed from the same plastic material (or a similar plastic material)that is used to form the housing 112. For example, both the offsetelement 302 and the housing 112 may be composed of the same moldablethermoplastic material. Accordingly, the offset element 302 could berealized as a one-piece component having certain physical featuresintegrally formed therein.

The offset element 302 generally includes, without limitation: a flatabutment surface 316 on its top housing side 317; an actuator side 318(under the top housing side 317) that mates with the piezoelectricspeaker 136; and an outer sidewall 320 extending from the actuator side318. The flat abutment surface 316 physically contacts and mates with aflat interior surface 322 of the rigid housing 112 when the electronicssubassembly 122 is inserted into the housing 112, as shown in FIG. 17.The actuator side 318 physically contacts and mates with a portion ofthe top major side 306 of the piezoelectric speaker 136. Thus, theactuator side 318 and the top housing side 317 of the offset element 302are separated by an offset thickness 324 (see FIG. 16). Moreover, theopening 314 extends from the actuator side 318 to the top housing side317, i.e., the height of the opening 314 corresponds to the offsetthickness 324.

Referring to FIG. 17, when the electronics assembly 122 is installed inthe housing 112, the piezoelectric speaker 136 will be enclosed withinthe housing 112. Moreover, the rim of the offset element 302 will belocated between the interior surface 322 of the housing 112 and thepiezoelectric speaker 136. For this particular embodiment, the outersidewall 320 of the offset element 302 surrounds the outer perimeter ofthe piezoelectric speaker 136. Thus, the piezoelectric speaker 136 is“nested” within the offset element 302 and it resides within an areadefined by the outer sidewall 320. The piezoelectric speaker 136 may beheld in position using tabs 325, flanges, or other features of theoffset element 302 (see FIG. 13, FIG. 15, and FIG. 16).

In accordance with well known principles, the piezoelectric speaker 136includes an actuator that is electrically controlled to vibrate andgenerate sound during operation of the fluid infusion device 100. Theoffset element 302 is designed to provide a resonant cavity 326 for thepiezoelectric speaker 136 (see FIG. 17). Notably, the offset element302, the opening 314, the offset thickness 324, the top major side ofthe piezoelectric speaker 136, and the interior surface 322 of thehousing 112 at least partially define this resonant cavity 326. Inpractice, the offset element 302, its opening 314, and its offsetthickness 324 are shaped, sized, and otherwise dimensioned such that theresonant cavity 326 causes air to resonate at a predetermined frequencyin response to activation of the piezoelectric speaker 136. In thisregard, the resonant cavity 326 may be designed to function as a“Helmholtz” cavity that is tuned to resonate at the desired frequency.

The use of the offset element 302 accommodates the “end loading”installation of the electronics assembly 122 into the housing 112, whilestill establishing and maintaining the desired resonant cavity 326. Asmentioned previously, the resilient mounting component 304 biases theoffset element 302 against the interior surface 322 of the housing 112,as depicted in FIG. 17. Thus, the dimensions of the resonant cavity 326are maintained after the fluid infusion device 100 has been assembled.

Resilient Cover For Electronics Assembly

Referring again to FIG. 2, the electronics assembly 122 is inserted as aunit into the housing 112. The electronics assembly 122 includes thecarrier substrate 134, the transducer assembly 300 mounted to thecarrier substrate 134, and other components. In certain embodiments, theelectronics assembly 122 includes a resilient cover 400, which isdepicted in FIG. 18. Another embodiment of this resilient cover 400(which lacks the central cross member) is depicted in FIG. 2 and FIG.11. The resilient cover 400 serves to protect the electronics assembly122, the display, and other delicate components under “drop and shock”conditions. The resilient cover 400 also serves to center the displaywithin the display window formed in the housing 112. The resilient cover400 is also suitably designed such that the electronics assembly 122 canbe easily installed into the housing 112 with little to no friction. Inthis regard, the resilient cover 400 may be coated with a lubricant or afriction-reducing substance that facilitates ease of assembly. Moreover,the resilient cover 400 functions as a seal or dust protector for threeof the four edges surrounding the display.

The resilient cover 400 is installed onto the electronics assembly 122such that it frames the liquid crystal display (LCD) assembly 402 andwraps around the various board components. Once installed, the resilientcover 400 absorbs assembly tolerances so that the positions of the LCDassembly 402 and electronics assembly 122 remain substantially fixedduring normal handling. The resilient cover 400 also forms a sealbetween the frame of the LCD assembly 402 and the interior surface ofthe housing 112, thus preventing dust from settling onto the front glasssurface of the LCD assembly 402. During a drop, impact, or shock, theresilient cover 400 absorbs and dissipates kinetic energy, thusprotecting the LCD assembly 402 and electronics assembly 122 fromdamage. The resilient cover 400 is also suitably designed to “spring”back into position such that the LCD display returns to its nominalcentered position relative to the display window of the housing 112.

Assembly Shim

The fluid infusion device 100 is assembled by loading its internalcomponents into the base end 116 of the housing 112 (see FIG. 2). Inthis regard, the fluid infusion device 100 is an end-loaded device.Thus, the various internal components are inserted into the housing 112and capped by another component, e.g., the housing end cap 114.

The main internal component, the electronics assembly 122, should bereadily installable with minimal force, be held in place so that the LCDdisplay aligns with the display window of the housing 112, and beretained in place firmly during operation. Accordingly, it is desirableto have an electronics assembly 122 that is easily inserted and, wheninside the housing 112, held firmly so that drops, shocks, vibrations,etc. do not significantly shift the position of the LCD display. Thus,the elastomeric resilient cover 400 and case bottom dampener (describedbelow) at the final assembly stage should be compressed within thehousing 112. The end load design of the fluid infusion device 100results in compression of the resilient cover 400 as it enters thehousing 112. The elastomeric material of the resilient cover 400 has arelatively high coefficient of friction, requiring high assembly forcesduring manufacturing, if not coated with friction-reducing coatings.

The fluid infusion device 100 also employs an assembly shim 410 thataddresses some of the manufacturing issues mentioned above. FIG. 19 isan exploded perspective assembly view of the fluid infusion device 100during a step in the manufacturing process, and FIG. 20 is a perspectiveview of the assembly shim 410 by itself. When the assembly shim 410 isused, the electronics assembly 122 can be end-loaded into the housing112 with little to no force or pressure. In other words, the electronicsassembly 122 by itself does not engage the housing with an interferencefit. Instead, when the electronics assembly 122 is fully inserted intothe housing 112, it remains relatively loose and “floating” in thehousing 112. Thereafter, the assembly shim 410 is inserted into thehousing 112 below the electronics assembly 122, as depicted in FIG. 19.The assembly shim 410 is formed of thermoplastic material with a lowercoefficient of friction than that of the resilient cover 400. Theassembly shim 410 biases the electronics assembly 122 upward (i.e.,toward the display window of the housing 112), and “locks” theelectronics assembly 122 in place within the housing 112. Oncepositioned in this manner, the electronics assembly 122 does not movewithin the housing 112. The biasing of the electronics assembly 122 inthis manner also sets the resilient cover 400 against the interiorsurfaces of the housing 112, which provides a degree of dust protection.

The assembly shim 410 also serves as a contact point for the case bottomdampener, which is described below in a separate section of thisspecification. Accordingly, the amount of compressive force imparted tothe assembly shim 410 (at the bottom of the housing 112) can be chosenby design of the assembly shim 410 and the case bottom dampener.

The assembly shim 410 also facilitates easy repairs and rework of thefluid infusion device 100. When the assembly shim 410 is removed fromthe housing 112, the electronics assembly 122 can be easily removed fromthe housing 112 for inspection, repair, or replacement without usingtweezers or pliers, and without having to bump or impact the housing 112to dislodge the electronics assembly 122.

The assembly shim 410 also functions as a cable or wire managementdevice for the fluid infusion device 100. In this regard, when theelectronics assembly 122 is inserted into the housing 112, there arevarious flex cables and wires protruding from the base end 116 of thehousing 112. These electrical conductors can be cumbersome to workaround and make it difficult to affix the housing end cap 114 to thehousing 112 (the cables and wires might interfere with the bonding orwelding of the of the housing end cap 114 to the housing 112, e.g.,contacting the housing end cap 114 before a weld is fully initiated).Referring to FIG. 20, the assembly shim 410 has an arm 412 that isconfigured to hold the various ribbon cables, wires, and otherelectrical conductors in their designated positions during and afterassembly. The shape, size, and form factor of the arm 412 contemplatesthe relative positioning and intended routing of the cables, wires, andconductors when the electronics assembly 122 and the assembly shim 410are fully inserted into the housing 112. In this manner, the assemblyshim 410 eliminates the need for assembly technicians to hold ormanipulate loose cables and wires between assembly steps and/or betweenassembly stations, and the assembly shim 410 allows the housing end cap114 to be easily attached to the housing 112.

Motor Support Cap

As mentioned above with reference to FIG. 2, the fluid infusion device100 may employ a motor support cap 128 that supports the drive motorassembly 124 and covers a portion of the force sensor 126. FIG. 21 is aperspective view of the motor support cap 128 by itself, FIG. 22 is atop view of the motor support cap 128, FIG. 23 is a front elevation viewof the motor support cap 128, and FIG. 24 is a side elevation view ofthe motor support cap 128. FIG. 25 is an exploded view of the fluidinfusion device 100, showing the motor support cap 128 in an uninstalledstate, and FIG. 26 is a perspective view of the fluid infusion device100 showing the installed state of the motor support cap 128.

The motor support cap 128 removes slack from assembly tolerancesassociated with the drive system, namely, the drive motor assembly 124.The motor support cap 128 is designed to tolerate very high impact loadin drop and shock conditions. The motor support cap 128 is an insertmolded component that has a high strength steel stamping 420 formed intothe desired shape. A polycarbonate material is molded over the stamping420 in a form that fits inside the housing 112 in the region below thedrive motor assembly 124. Polycarbonate is used because of its opticalproperties so that ultraviolet (UV) light can shine through and cure anadhesive to secure the motor support cap 128 to the inside wall of thehousing 112. The composite combination of metal and plastic provides therequired rigidity and assembly flexibility.

For assembly, the motor support cap 128 is placed such that it coversand supports the end of the drive motor assembly 124 and the forcesensor 126 (see FIG. 25). Once the motor support cap 128 is in place, aUV cure adhesive is applied around the polycarbonate perimeter 422 ofthe motor support cap 128. In its uncured state, the UV adhesive can rundown the side in a gap between the motor support cap 128 and the innerwall of the housing 112 (assuming that the housing 112 is held in anupright orientation such as that depicted in FIG. 25). To keep theadhesive from running too far into the housing 112, and possibly stayingon the drive motor assembly 124, a horizontal rib 424 is molded aroundthe bottom of the perimeter 422 to act as a dam for the adhesive.Moreover, vertical ribs 426 are formed in the polycarbonate (at the endsand intermittently around the perimeter 422) to compartmentalize the UVadhesive and to minimize build up of the adhesive. The vertical ribs 426help to create and maintain the desired gap for the adhesive. Thisallows delivery of the UV cure adhesive to be more evenly distributedand to completely fill in the gap formed between the motor support cap128 and the housing 112. The motor support cap 128 has the added benefitof eliminating a leak path from the housing 112. Moreover, the shockload from the drive system is transferred to the housing 112 and not thehousing end cap 114. This allows the dispersion of the load to thelarger mass of the housing 112 instead of the smaller housing end cap114.

Case Bottom Dampener

Certain embodiments of the fluid infusion device 100 employ a cushioningelement between the housing end cap 114 and the internal componentsinside the housing 112. In this regard, FIG. 27 is an exploded frontperspective view of the fluid infusion device 100, and FIG. 28 is anexploded rear perspective view of the fluid infusion device 100. FIG. 27and FIG. 28 both depict the fluid infusion device 100 before the housingend cap 114 has been attached to the base end 116 of the housing 112.These figures also show a case bottom dampener 430 prior toinstallation. The case bottom dampener 430 is formed from a resilientmaterial such as rubber, polyurethane, foam, or the like. The casebottom dampener 430 has features and characteristics (e.g., ribs,protrusions, shoulders) that facilitate positioning relative tocorresponding features formed on the housing end cap 114 and/orcorresponding features of the internal components of the fluid infusiondevice 100.

When assembled, the electronics assembly 122 (see FIG. 2) is locatedinside the housing 112 and is positioned by one or more resilientcomponents (dampeners) such as the assembly shim 410 described above.The case bottom dampener 430 is installed onto the interior surface ofthe housing end cap 114 before the housing end cap 114 is attached tothe housing 112. The case bottom dampener 430 provides a slightpositional bias and loading upon the electronics assembly 122 within thehousing 112. This loading helps to absorb assembly tolerances so thatthe position of the electronics assembly 122 is fixed during normalhandling of the fluid infusion device 100. During a drop, impact orshock, the case bottom dampener 430 acts to absorb and dissipate kineticenergy, thus protecting the electronics assembly 122 from damage. Thecase bottom dampener also provides enough rebound force to push theelectronics assembly 122 back into its nominal position, thus ensuringthat the LCD display is centered with respect to the display window ofthe housing 112.

Thermoplastic Adhesive For Housing End Cap

As mentioned previously, the fluid infusion device 100 is assembled byend-loading all internal components into the housing 112 and bonding thehousing end cap 114 onto the housing 112 in order to seal the unit. Inpreferred embodiments, the housing end cap 114 is ultrasonically weldedto the end of the housing 112 utilizing a double shear weld joint toproduce a water resistant seal (to satisfy specifications such as, forexample, IPX8). This bond interface can be further improved by adding abead of thermoplastic adhesive to the groove within the housing end cap114, as depicted in FIG. 29. As shown in FIG. 29, the housing end cap114 includes a groove 440 around its edge; this groove 440 mates with acorresponding lip 442 of the housing 112.

During assembly, the thermoplastic adhesive is applied to the groove 440and/or to the lip 442 before the housing end cap 114 is secured to thehousing 112. Thereafter, the joint is subjected to an ultrasonic weldingprocess. The heat generated during the ultrasonic welding operationserves to melt the thermoplastic adhesive, causing it to flow into anyremaining crevasses between the housing 112 and the housing end cap 114.The flow and subsequent solidification of the thermoplastic adhesiveimproves the sealing capability as well as the strength of the bondbetween the housing 112 and the housing end cap 114.

Keypad Overlay Sealing And Graphic Keypad Overlay

In contrast to conventional designs that use a graphical keypad overlayto form a water resistant seal with the device housing, the fluidinfusion device 100 uses a distinct sealing element and/or a keypadactuator layer to form the seal. FIGS. 30-33 illustrate an exemplaryembodiment that includes this feature. FIG. 30 is a perspective frontview of the housing 112 of the fluid infusion device 100, FIG. 31 is across sectional view of the housing 112 as viewed from line 31-31 inFIG. 30, FIG. 32 is a perspective front view of a membrane keypadassembly 500 suitable for use with the fluid infusion device 100, FIG.33 is a perspective front view of the fluid infusion device 100 prior toinstallation of a keypad actuator layer 502, and FIG. 34 is aperspective front view of the fluid infusion device 100 prior toinstallation of a graphic keypad overlay 503.

Referring to FIG. 30 and FIG. 31, the housing 112 has a front face 504,which generally corresponds to the front major side of the fluidinfusion device 100, i.e., the side having the display and primary userinterface features. In certain embodiments, the front face 504 includesone or more mounting features or elements formed therein. For example,the illustrated embodiment includes a keypad mounting cavity 506integrally formed in the front face 504 of the housing 112. The keypadmounting cavity 506 is one suitable implementation of a keypad mountingarea that is shaped and sized to accommodate the keypad assembly 500.The keypad mounting cavity 506 is preferably dimensioned such that thekeypad assembly 500 fits within its border. In this regard, theillustrated example employs a rectangular keypad mounting cavity 506having a depth that allows the keypad assembly 500 to sit inside thekeypad mounting cavity 506 without protruding. In FIG. 31, the keypadmounting cavity 506 is centrally located and has a width that isidentified by the arrow 507. The housing 112 may also have a hole or aslot 508 formed therein to accommodate a flex circuit tail, wires, orother electrical conductors of the keypad assembly 500. As shown in FIG.30, the slot 508 is located within the area defined by the keypadmounting cavity 506.

The front face 504 also includes a sealing surface surrounding thekeypad mounting cavity 506. For this particular embodiment, the sealingsurface is realized as a sealing rim 510 that is integrally formed aspart of the housing 112 (the sealing rim 510 corresponds to the shadedarea in FIG. 30). The sealing rim 510 is located outside and around thekeypad mounting cavity 506, and the upper surface of the sealing rim 510resides above the base of the keypad mounting cavity 506, as shown inFIG. 31. The sealing rim 510 is shaped, sized, and dimensioned toaccommodate a sealing element and/or the keypad actuator layer 502 ofthe fluid infusion device 100. In this regard, the sealing rim 510 ispreferably dimensioned such that the sealing layer fits within itsborder. The illustrated example employs a rectangular ring-shapedsealing rim 510 having a depth that allows the sealing member to sitrecessed within the housing 112. FIG. 31 depicts how the sealing rim 510extends beyond the keypad mounting cavity 506 (the sealing rim 510defines a relatively shallow step outside the perimeter of the keypadmounting cavity 506.

Referring now to FIG. 32, the keypad assembly 500 is preferably realizedas a membrane keypad assembly, which can be fabricated in accordancewith well known techniques and technology. The keypad assembly 500includes actuation components 512 integrated therein, and a flex circuittail 514 having electrical conductors coupled to the actuationcomponents 512. In a practical embodiment, the actuation components 512may be realized as metal domes arranged in two dome arrays, stacked tocreate a double-stacked metal dome assembly. In certain implementations,the flex circuit tail 514 is formed from a polyimide material thatserves as a carrier for electrical conductors. Although the exact numberof actuation components 512 may vary from one device to another, theillustrated embodiment of the keypad assembly 500 has seven. Afterassembly of the fluid infusion device 100 is complete, the actuationcomponents 512 can be manipulated and actuated to control operation ofthe fluid infusion device 100.

During assembly of the fluid infusion device 100, the membrane keypadassembly 500 is positioned in the keypad mounting cavity 506 of thehousing 112, and it is electrically connected such that it interfaceswith the interior electronics assembly 122 by way of the polyimide flexcircuit tail 514. In this regard, the flex circuit tail 514 is routedthrough the slot 508 before the keypad assembly 500 is secured to thehousing 112 (see FIG. 33). An adhesive or double backed tape can be usedto affix the keypad assembly 500 to the housing 112.

Referring to FIG. 33, the keypad actuator layer 502 serves as a sealingelement for the keypad assembly 500, and it inhibits fluid incursioninto the housing 112. The keypad actuator layer 502 is formed from aflexible material such as plastic, polyester, polyurethane, or the like.In certain preferred embodiments, the keypad actuator layer 502 isnon-decorative, non-cosmetic, and free of printed graphics (e.g.,ink-based graphics). In particular, the bottom surface of the keypadactuator layer 502 should be free of decoration, ink, paint, or othersubstances that are prone to peeling or flaking, for reasons explainedbelow.

The keypad actuator layer 502 includes protrusions 516 corresponding tothe actuation components 512 of the underlying keypad assembly 500.These protrusions 516 may extend from the upper surface and/or the lowersurface of the keypad actuator layer 502. After the keypad actuatorlayer 502 is installed overlying the keypad assembly 500, theprotrusions 516 will be overlying and aligned with their respectiveactuation components 512. The protrusions 516 facilitate actuation ofthe underlying actuation components 512 by concentrating user-appliedforces at or near the actuation components 512.

The keypad actuator layer 502 has a perimeter area 518 that extendsbeyond the keypad assembly 500. For the illustrated embodiment, theperimeter area 518 corresponds to an outer rectangular ring-shapedboundary of the keypad actuator layer 502. Accordingly, the keypadactuator layer 502 completely covers and overlies the keypad assembly500 (after assembly), as shown in FIG. 34. In this regard, the keypadactuator layer 502 is shaped and sized to fit within the shallowdepression formed by the sealing rim 510. Moreover, the perimeter area518 of the keypad actuator layer 502 is coupled to the sealing rim 510in a manner that forms a fluid resistant seal between the housing 112and the keypad actuator layer 502.

During assembly of the fluid infusion device 100, a suitable adhesive(e.g., a polyester thermoplastic adhesive) is applied to the bottomsurface of the perimeter area 518 and/or to the sealing rim 510, and thekeypad actuator layer 502 is properly aligned and placed overlying thekeypad assembly 500, such that the perimeter area 518 is aligned withthe sealing rim 510. Thereafter, pressure and heat are applied to thetop surface of the perimeter area 518 overlying the sealing rim 510,resulting in the melting, curing, or activation of the thermoplasticadhesive and the bonding of the keypad actuator layer 502 to the sealingrim 510 of the housing 112. The resulting plastic-to-plastic bond formsa fluid resistant seal between the housing 112 and the keypad actuatorlayer 502, which inhibits fluid such as water from reaching theunderlying keypad assembly 500 or internal electronics. Notably, thelack of printed graphics, ink, and other removable substances on atleast the perimeter area 518 of the keypad actuator layer 502 enhancesthe integrity, reliability, and robustness of this seal.

The embodiment described here uses the keypad actuator layer 502 as thesealing layer. Alternatively (or additionally), a distinct sealingelement or layer could be used to form the water resistant seal at thehousing 112. For example, a sealing film having an appropriate perimeterarea could be applied overlying the keypad assembly 500 and the keypadactuator layer 502, where the sealing film (rather than the keypadactuator layer 502) is bonded to the sealing rim 510 of the housing 112.For the same reasons mentioned above, the sealing film should be free ofany printed graphics, ink, or other substances that might peel or flakeaway.

Referring to FIG. 34, the graphic keypad overlay 503 is applied to thetop surface of the keypad actuator layer 502 by use of pressuresensitive adhesive, double backed tape, or the like. For this particularembodiment, the graphic keypad overlay 503 provides no sealing functionand is applied to the fluid infusion device 100 near the end of themanufacturing process. Moreover, the graphic keypad overlay 503 isdesigned to be easily removable and replaceable to accommodate usercustomization and personalization. This also facilitates the use ofdifferent labeling, branding, and color schemes. The relief geometry ofthe graphic keypad overlay 503 is customizable to allow differentaesthetics, tactile feel, and haptic response. Such customization allowsgeneric fluid infusion devices to be created and stocked and thereaftercustomized with an appropriately stylized graphic keypad overlay 503 tocreate a specific final assembly appearance.

During assembly, the graphic keypad overlay 503 is adhered to the keypadactuator layer 502 (or to whatever sealing element is used) in thedesired orientation. In this regard, the graphic keypad overlay 503 willtypically include graphical representations 520 corresponding to theunderlying protrusions 516 and the underlying actuation components 512.Thus, the graphical representations 520 are aligned with the actuationcomponents 512 to provide visual guidance to the user. In certainembodiments, the graphic keypad overlay 503 is formed from a clearplastic film having a top surface 522, a bottom surface 524, andgraphics printed on or otherwise applied to the bottom surface 524.Accordingly, the graphic keypad overlay 503 is adhered to the keypadactuator layer 502 such that the bottom surface 524 and the graphicsface the keypad actuator layer 502, and such that the top surface 522 isexposed. This arrangement protects the graphics, which remain visiblethrough the clear plastic film that forms the graphic keypad overlay503.

As mentioned above, the graphic keypad overlay 503 is removably adheredto the keypad actuator layer 502 to facilitate replacement or “skinning”of the fluid infusion device 100. In this regard, the fluid infusiondevice 100 or its case assembly could be provided as a kit with aplurality of different graphic keypad overlays, each having a visuallydistinct set of graphical features corresponding to the actuationcomponents 512, and each being configured for removable adhesion to thekeypad actuator layer 502. In practice, therefore, the adhesive used forthe graphic keypad overlay 503 should be weaker than the adhesive usedto secure the keypad actuator layer 502 to the sealing rim 510. In otherwords, it may be desirable to intentionally establish a temporary bondbetween the graphic keypad overlay 503 and the keypad actuator layer502, while maintaining a “permanent” bond between the keypad actuatorlayer 502 and the housing 112. Thus, repeated removal of the graphickeypad overlay 503 should not adversely impact the integrity of the sealbetween the perimeter area 518 and the sealing rim 510.

Ambient Light Sensor

The fluid infusion device 100 may also include a light sensor 602 thatis capable of sensing ambient light levels and providing related outputsignals to the electronics assembly 122 (see FIG. 33 and FIG. 34). Inpractice, a light sensor could be located anywhere on the housing 112 orelsewhere on the fluid infusion device 100. For this particularimplementation, the light sensor 602 is integrated into the polyimideflex circuitry of the membrane keypad assembly 500. The light sensor 602is located beneath a partially translucent (dead front) window of theoverlying graphic keypad overlay 503, which transmits light. Therecorded level of ambient light can be used to control the LED backlightintensity of the LCD display as well as the LED backlight intensityunder each of the keypad button icons located on the graphic keypadoverlay 503.

Alarm Or Fault LED

The fluid infusion device 100 may also include an alarm/fault LED 604located on the housing 112, at or near the user interface, or elsewhere.As shown in FIG. 33, the alarm/fault LED 604 may be located underlyingthe graphic keypad overlay 503. The alarm/fault LED 604 can be activatedwhen the fluid infusion device 100 experiences an alert, alarm, orunrecoverable fault. Depending on the alert/alarm/fault state, thealarm/fault LED 604 might blink at a prescribed frequency, becontinuously lit, or flash in a particular pattern. The goal of thealarm/fault LED 604 is to inform the user that an alert, alarm, or faulthas occurred and that appropriate action should be taken. For thisparticular implementation, the alarm/fault LED 604 is integrated intothe polyimide flex circuitry of the keypad assembly 500. The alarm/faultLED 604 is located beneath a partially translucent (dead front) windowwithin the overlying graphic keypad overlay 503.

Decorative Back Cover

The fluid infusion device 100 may also be designed to accommodate adecorative back cover that is applied to the rear surface of the housing112. In this regard, FIG. 35 is a perspective back view of the fluidinfusion device 100 prior to installation of a decorative back cover610. The decorative back cover 610 can be either a rigid plastic sheetthermoformed to match the curve or contour of the rear surface 612 ofthe housing 112, or a flexible sheet capable of adapting to the contourof the rear surface 612. The conforming shape of the decorative backcover 610 facilitates easy assembly onto the housing 112.

The decorative back cover 610 is retained on the case with pressuresensitive adhesive, double backed tape, by a press fit engagement, or bya snap fit engagement. The graphics and/or texture of the decorativeback cover 610 are customizable and such customization allows genericdevice assemblies to be created and stocked until such time a stylizeddecorative back cover 610 is applied to create a specific finalassembly. The decorative back cover 610 is designed to be removed andreplaced by the end user in the field; thus extra decorative back coverscan be made available for purchase by end users.

Belt Clip With Integrated Screwdriver

FIG. 36 is a side view of a belt clip 700 suitable for use with thefluid infusion device 100, and FIG. 37 is an exploded perspective viewof the belt clip 700. The illustrated embodiment of the belt clip 700generally includes, without limitation: a base 702; a mount 704; aspring 706 (only a small portion of which is visible in FIG. 36); and ahinge pin 708. The base 702 and the mount 704 are pivotally coupledtogether using the hinge pin 708. The hinge pin 708 passes through thebody of the spring 706, such that the spring 706 nominally biases thebase 702 and the mount 704 toward each other. The belt clip 700generally functions in accordance with conventional belt clips in thatan inward force 710 (see FIG. 36) at the upper ends of the base 702 andthe mount 704 will force the lower end of the mount 704 away from thebase 702.

The mount 704 is shaped, sized, and configured to mate with acorresponding receptacle 712 integrated in or otherwise located at theback of the fluid infusion device 100 (see FIG. 35). For this particularembodiment, the mount 704 slides into the receptacle and is removablysecured therein by a snap fit or a press fit engagement. Thus, the fluidinfusion device 100 can be worn by placing the base 702 behind theuser's belt, inside the user's pocket, inside the waistline of theuser's pants, etc.

The belt clip 700 includes a screwdriver tip integrated therein. Thescrewdriver tip may be fabricated as part of the base 702 or as part ofthe mount 704. In certain embodiments, one screwdriver tip could belocated on the base 702 and another screwdriver tip could be located onthe mount 704. The exemplary embodiment shown in FIG. 36 and FIG. 37includes a screwdriver tip 720 formed on the base 702. Morespecifically, the screwdriver tip 720 is formed at the lowermost end 722of the base 702. The base 702 may be fabricated from a hard and toughmolded plastic material such that the screwdriver tip 720 is created asan integrated feature that is continuous and contiguous with the otherfeatures of the base 702. Although not always required, the base 702 maybe manufactured with reinforcing material or components at or near thescrewdriver tip 702 to provide additional structural integrity.

The screwdriver tip 702 is shaped and sized to mate with one or morecomponents or elements of the fluid infusion device 100. For example,the screwdriver tip 702 could be designed to fit an adjustment screw,the battery cap 129 (see FIG. 35), a lock mechanism, or the like. Asshown in FIG. 35, the battery cap 129 includes a slot 726 formedtherein. The screwdriver tip 702 is shaped and sized to fit this slot726. Accordingly, when the battery needs to be replaced, the user cansimply detach the fluid infusion device 100 from the mount 704, and thenuse the freed belt clip 700 (more specifically, the screwdriver tip 720)as a screwdriver to remove and replace the battery cap 129 from thehousing 112. It should be appreciated that the screwdriver tip can beshaped and sized as desired for purposes of matching the desiredfeatures. For example, although the illustrated screwdriver tip 720 isdesigned to mate with a straight slot, alternate embodiments could bedesigned to mate with a crosshead slot, a star-shaped hole or cavity, atriangular hole or cavity, or the like.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

What is claimed is:
 1. A shock absorbing element for a battery of amedical device having a battery receptacle for the battery and having anelectrical contact for the battery, the electrical contact residingwithin the battery receptacle, the shock absorbing element composed of aresilient material and comprising: a perimeter sized and shaped toaccommodate placement in the battery receptacle; a through hole formedin the resilient material, the through hole being sized and shaped toaccommodate the electrical contact; a first side; a second side; andshock absorbing features formed on the first side or the second side todissipate kinetic energy associated with motion of the battery relativeto the battery receptacle, wherein the shock absorbing featurescomprise: a plurality of angled outer depressions, each having arespective high edge near the through hole and having a respective lowedge near the perimeter; and a plurality of angled inner depressions,each having a respective high edge near the perimeter and having arespective low edge near the through hole.
 2. The shock absorbingelement of claim 1, wherein the shock absorbing element is a one-piececomponent composed of the resilient material.
 3. The shock absorbingelement of claim 1, wherein: the perimeter is generally circular; thethrough hole is generally round; and the perimeter and the through holeare coaxial.
 4. The shock absorbing element of claim 3, wherein theshock absorbing features comprise radial ridges formed from theresilient material.
 5. The shock absorbing element of claim 3, whereinthe shock absorbing features comprise radial depressions formed in theresilient material.
 6. The shock absorbing element of claim 1, whereinat least one of the shock absorbing features is formed on the firstside, and at least one of the shock absorbing features is formed on thesecond side.
 7. The shock absorbing element of claim 1, wherein: atleast one of the of angled outer depressions is formed on the firstside; at least one of the of angled inner depressions is formed on thefirst side; at least one of the of angled outer depressions is formed onthe second side; and at least one of the of angled inner depressions isformed on the second side.
 8. The shock absorbing element of claim 7,wherein: each angled outer depression formed on the first side isaligned with a respective angled inner depression formed on the secondside; and each angled outer depression formed on the second side isaligned with a respective angled inner depression formed on the firstside.
 9. The shock absorbing element of claim 1, wherein the resilientmaterial is an electrical insulator.
 10. A shock absorbing assembly fora battery of a medical device, the shock absorbing assembly comprising:a battery sleeve to house the battery, the battery sleeve having a baseend; an electrical contact for the battery, the electrical contactresiding within the battery sleeve near the base end; and a shockabsorbing element located within the battery sleeve near the base end,the shock absorbing element composed of a resilient material havingshock absorbing features integrally formed therein to dissipate kineticenergy associated with motion of the battery toward the base end,wherein the shock absorbing features comprise: a plurality of angledouter depressions, each having a respective high edge near the throughhole and having a respective low edge near the perimeter; and aplurality of angled inner depressions, each having a respective highedge near the perimeter and having a respective low edge near thethrough hole.
 11. The shock absorbing assembly of claim 10, wherein theshock absorbing element is ring-shaped and surrounds the electricalcontact.
 12. The shock absorbing assembly of claim 10, wherein the shockabsorbing element is attached to the base end.
 13. The shock absorbingassembly of claim 10, wherein the shock absorbing element is a one-piececomponent composed of the resilient material.
 14. The shock absorbingassembly of claim 10, wherein the resilient material is an electricalinsulator.
 15. The shock absorbing assembly of claim 10, wherein theelectrical contact comprises an electrically conductive spring.
 16. Aportable medical device comprising: a housing; a battery sleeve insidethe housing, the battery sleeve having a base end, wherein the batterysleeve accommodates a battery for the portable medical device; a batterycontact located inside the battery sleeve near the base end; and aresilient and compressive element located inside the battery sleeve nearthe base end, the battery contact protruding through the resilient andcompressive element, wherein the resilient and compressive elementdissipates kinetic energy associated with motion of the battery towardthe base end, wherein the resilient and compressive element comprisesshock absorbing features integrally formed therein, the shock absorbingfeatures comprising: a plurality of angled outer depressions, eachhaving a respective high edge near the through hole and having arespective low edge near the perimeter; and a plurality of angled innerdepressions, each having a respective high edge near the perimeter andhaving a respective low edge near the through hole.
 17. The portablemedical device of claim 16, wherein the battery sleeve is shaped andsized to accommodate a AA battery.
 18. The portable medical device ofclaim 16, wherein the resilient and compressive element is coupled tothe base end such that it resides between the base end and the battery.19. The portable medical device of claim 16, wherein the battery contactcomprises an electrically conductive spring.
 20. The portable medicaldevice of claim 16, further comprising infusion pump hardware and anelectronics module associated with the infusion pump hardware, whereinthe battery serves as a power supply for the infusion pump hardware andthe electronics module.